Case 2 FORM 2
THE PATENTS ACT, 1970 (39 of 1970)
As amended by the Patents (Amendment) Act, 2005
&
THE PATENTS RULES, 2003
As amended by the Patents (Amendment) Rules, 2006
PROVISIONAL SPECIFICATION
(See section 10 and rule 13)
TITLE OF THE INVENTION
Filled polyolefin compositions having improved mechanical and surface properties
APPLICANTS
Name : Reliance Industries Limited
Address : 5th Floor, Maker Chamber IV, Nariman Point,Mumbai 400 021, Maharashtra, India
Nationality : an Indian Company
PREAMBLE TO THE DESCRIPTION
The following specification describes the invention. :

Field of invention
The invention relates to filled polyolefin compositions having improved mechanical and surface properties and to a process for preparing them.
Background
Filled polyolefin compositions find a variety of applications. They are extensively used in the manufacture of various articles and products. They are usually prepared by melt mixing a polyolefin with an inorganic filler at a temperature above the melting point of the polyolefin. In order to increase the durablility and to improve the aesthetic appeal of the articles and products manufactured by filled polyolefin compositions, it is required that the compositions have good mechanical and surface properties.
Detailed Description of Invention
Accordingly, the invention provides a composition of polyolefin reinforced with filler(s), impact modifier(s) and fibrous sub micron structured material(s), the composition having improved surface properties, mechanical properties and crystallinity, the composition comprising atleast two polyolefins, one polyolefin having high melt flow index (MFI) and another polyolefin having low melt flow index.
The invention also provides a process for preparing a filled polyolefin composition by melt mixing a mixture of polyolefins, impact modifiers), fibrous sub micron structured material(s) and filler(s), the mixture comprising at least two polyolefins, one polyolefin having a higher MFI than the other. Melt mixing is carried out at a specific energy in the range of 0.1 to 2.5 Kw Hr./kg, preferably in the range of 0.3 to 1.5 Kw Hr./kg in an extruder. During the process of the invention, temperature of the extruder is maintained between 150°C to 220°C, preferably between 160°C-190°C.
In the composition of the invention, polyolefin is present in around 53-95.99% by weight of composition, preferably in the range of 64-91.9% by weight of
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composition, the low MFI polyolefin being present in around 60-95 % by weight of polyolefin, preferably in the range of 70-95 % by weight of polyolefin, the high MFI polyolefin being present in around 5-40% by weight of polyolefin, preferably in the range of 5-30% by weight of polyolefin, the filler being present in around 1-20% by weight of composition, preferably in the range of 3-15% by weight of composition, the impact modifier being present in around 3-25% by weight of composition, preferably in the range of 5-20% by weight of composition and the fibrous sub micron structured material being present in around 0.01-2% by weight of composition, preferably in the range of 0.1-1% by weight of composition.
Low MFI polyolefin used in the invention is preferably one selected from the group consisting of polypropylene having MFI in the range of 0.3-15 g/lOmin, polyethylene having MFI in the range of 0.1-15 g/l0min and ethylene-propylene copolymer having MFI in the range of 0.25-15 g/l0min. The high MFI polyolefin is preferably one selected from the group consisting of polypropylene having MFI in the range of 16-60 g/l0min, polyethylene having MFI in the range of 16-60 g/l0min and ethylene-propylene copolymer having MFI in the range of 16-60 g/l0min. Polyolefins used in the invention are thermoplastic and/or crosslinkable polyolefins. Propylene-ethylene copolymer is a random, block or graft copolymer.
The fillers used in the invention include fillers and solid compounding ingredients or agents used in polymeric compounds. Typical fillers include all kinds of clays, layered silicate materials, carbon black, wood flour either with or without oil, various forms of silica including common sand, glass, metals, and oxides of metals such as aluminum oxide and titanium oxide, aluminum trihydrate and titanium dioxide magnesium oxide, calcium carbonate, barium carbonate, magnesium carbonate, barium sulfate, antimony trioxide, calcium silicate, diatomaceous earth, fuller earth, kieselguhr, mica, talc, slate flour, volcanic ash, cotton flock, asbestos, kaolin, sulfates of barium, calcium sulfate, titanium, nano clay, zeolites, vanadium oxide, wollastonite, titanium boride, zinc borate, tungsten carbide, ferrites, molybdium disulfide, asbestos, cristobalite, silica and layered silicate materials including Vermiculite, bentonite, montmorillonite, Na-montmorillonite, Ca-montmorillonite, kaolinite, mica, hectorite, fluorohectorite, saponite, beidelite, nontronite, stevensite, vermiculite, hallosite, volkonskoite, suconite, magadite and kenyalite in the modified
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or unmodified form. Modifiers are usually organic substances having atleast one functional group selected from primary ammonium to quaternary ammonium, phosphonium, maleate, succinate, acrylate, benzylic hydrogen, oxazoline, and dimethyldistearylammonium groups. Aluminosilicates like calcium aluminum magnesium silicate hydroxide, pyrophyllite, magnesium aluminum silicate, lithium aluminium silicates and zirconium silicates as well as silica which includes precipitated or hydrated, fumed or pyrogenic, vitreous, fused or colloidal and hydroxides of aluminium or ammonium or magnesium, zirconia, nanoscale titania and their suitable combinations are also used as fillers. Inorganic oxide or mixture of two or more inorganic oxides are also used as fillers to prepare the composition of the invention. Such fillers include oxides of the metals in periods 2, 3, 4, 5 and 6 of Groups Ib, IIb, IIa, IIIb, IVa, IVb (except carbon), Va, Via, Villa and VIII of the Periodic Table.
The fillers could also be fibrous fillers which include fibers like glass fibers, basalt fibers, aramid fibers, carbon fibers, carbon nanofibers, melamine fibers, polyamide fibers, metal fibers. Fillers like carbon nanotubes, carbon buckyballs, potassium titanate whiskers, aluminum borate whiskers can also be used. Preferred fillers are selected from the group consisting of calcium carbonate, talc, glass fibers, carbon fibers, mica, kaolin, wollastonite, calcium sulfate, barium sulfate, titanium, silica, carbon black and their suitable combinations.
When a layered silicate material is used as filler in the composition, it is optionally pre-blended with functionalized polyolefin. The functionalized polyolefin is at least one compound selected from the group consisting of but not limited to ethylene-ethylene anhydride-acrylic acid copolymer, ethylene-ethyl acrylate copolymer,efhylene-alkyl acrylate-acrylic acid copolymer, maleic anhydride modified (graft) polyethylenes, ethylene-alkyl (meth) acrylate-(meth)acrylic acid copolymer, ethylene-butyl acrylate copolymer, ethylene-vinyl acetate copolymer, maleic anhydride modified (graft) ethylene-vinyl acetate copolymer and maleic anhydride modified polypropylenes.
Any elastomer or rubbery material in any form can be used as impact modifier. The impact modifier is typically a copolymer or terpolymer, consisting of monomers
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selected from ethylene, C3-20 a-olefins and unsaturated comonomers like C4.20 dienes, vinyl aromatic compounds, (meth)acrylic compounds and (meth)acrylate compounds. The copolymer or terpolymer is a random, block or graft copolymer. The impact modifier is optionally a blend of (homo/co)polyolefins and rubber, in varied relative amounts of each component. Preferably, impact modifiers based on Ethylene-a-olefin copolymers are used.
The fibrous sub micron structured material in the composition is at least one selected from UHMWPE (Ultra High Molecular Weight Polyethylene), cellulosic material or fluoropolymers. Suitable fluoropolymers include homopolymers and copolymers comprising structural units derived from one or more fluorinated alpha-olefin monomers, that is, an alpha-olefin monomer that includes at least one fluorine atom in place of a hydrogen atom. In one embodiment the fluoropolymer comprises structural units derived from two or more fluorinated alpha-olefin, for example tetrafluoroethylene, hexafluoroethylene, and the like. In another embodiment, the fluoropolymer comprises structural units derived from one or more fluorinated alpha-olefin monomers and one or more non-fluorinated monoethylenically unsaturated monomers that are copolymerizable with the fluorinated monomers, for example alpha-monoethylenically unsaturated copolymerizable monomers such as ethylene, propylene, butene, acrylate monomers (e.g., methyl methacrylate and butyl acrylate), vinyl ethers, (e. g., cyclohexyl vinyl ether, ethyl vinyl ether, n-butyl vinyl ether, vinyl esters) and the like. Specific examples of fluoropolymers include polytetrafluoroethylene, polyhexafluoropropylene, polyvinylidene fluoride, polychlorotrifluoroethylene, ethylene tetrafluoroethylene, fluorinated ethylene-propylene, polyvinyl fluoride, and ethylene chlorotrifluoroethylene. Combinations comprising at least one of the foregoing fluoropolymers may also be used
The filled polyolefin compositions of the invention are molded into useful articles by a variety of means like injection molding, extrusion molding, rotation molding, foam molding, calendar molding, blow molding, thermoforming, compaction and melt spinning. The articles so formed can be additionally molded, mold-decorated, baked, laminated and/or thermoformed. The articles made from the composition of the invention find applications in telecommunication and automotive industry as well as in the manufacture of home appliances and electrical components.
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The composition of the invention can be used for manufacturing various articles and products including aircrafts, automotives, trucks, military vehicles and of components such as panels, quarter panels, rocker panels, trim, fenders, doors, decklids, trunk lids, hoods, bonnets, roofs, bumpers, fascia, grilles, mirror housings, pillar appliques, cladding, body side moldings, wheel covers, hubcaps, door handles, spoilers, window frames, headlamp bezels, headlamps, tail lamps, tail lamp housings, tail lamp bezels, license plate enclosures, roof racks, and running boards; enclosures, housings, panels, parts for outdoor vehicles and devices; enclosures for electrical and telecommunication devices; outdoor furniture and aircraft components. The composition is also suitable for the manufacture of boats and marine equipments, including trim, enclosures, and housings; outboard motor housings; depth finder housings, personal water-craft; jet-skis; pools; spas; hot-tubs; steps; step coverings and for building and construction applications such in glazing and in the manufacture of roofs, windows, floors, decorative window furnishings; treated glass covers for pictures, paintings, posters, display items; wall panels, and doors; counter tops; protected graphics; outdoor and indoor signs; enclosures, housings, panels, parts for automatic teller machines (ATM); computer and computer peripherals; FAX machine; copier; telephone; phone bezels; mobile phone; radio sender; radio receiver; enclosures, housings, panels, and parts for lawn and garden tractors, lawn mowers, and tools, including lawn and garden tools; window and door trim; sports equipment and toys; enclosures, housings, panels, and parts for snowmobiles; recreational vehicle panels and components; playground equipment; shoe laces; articles made from plastic-wood combinations; golf course markers; utility pit covers; light fixtures; lighting appliances; network interface device housings; transformer housings; air conditioner housings; cladding or seating for public transportation; cladding or seating for trains, subways, or buses; meter housings; antenna housings; cladding for satellite dishes; coated helmets and personal protective equipment; coated synthetic or natural textiles; coated painted articles; coated dyed articles; coated fluorescent articles; coated foam articles; multilayered and bubble guard sheets, pipes; oriented polyolefin composite articles using films, tape, fiber, yarn or sheets; raffia bags or the like. Because of the improved mechanical and surface properties of the composition of the invention, it can be used for a larger and wider range of products and articles. The articles and products manufactured by the composition of the invention can
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withstand extremely harsh environments and ultraviolet light. Durability and life of the products and articles are improved. Aesthetic appeal of the products and articles is improved.
Dated this the 24thday of May 2007

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